Plastic composition and method of producing the same.



106. COMPOSITIONS, 3 F 5 COATING R PLASTIC. 7,5 I v UNITED STATES PATENT OFFICE.

WILLIAM H. WHEELER, OF SOMERSET, NEW JERSEY.

PLASTIC COMPOSITION AND METHOD OF PRODUCING THE SAME.

1,201,535. Specification of Letters Patent Patented Oct. 17, 1 916. No Drawing. I Application filed larch 3, 1915. Serial No. 11,902.

To all'whom it may concern: which I preferably employ is odium sili- Be it known that I,WILLIAM H. WHEELER, cate, but may be otassium silicate under a citizen of the United States, and resident some conditions or circumstances I)? manuof the county of Somerset, in the State of facture and use. The solid binding mate- 6) New Jersey, have invented certain new and rial, having the character above set forth, useful Improvements in Plastic Composimay be one of the class of cements, such as tions and Methods of Producing the Same, Portl gd gm%n. blast furnacg figment, or of which the following is a specification. na ura cemen or 1115 ance, any rue ort- My invention relates to compositions of land cement or other cement having a sub- 85 o matter'for use as a substitute for wood in stantial proport on 0 ca cium oxid, ut

building construction and analogous purpre era y employ a hydraulic cement of a poses, and it has for its object to produce an character which sets in a large excess of waimproved fireproof composition of this charter, such as hydraulic Portland cement.

acter which will possess enhanced charac- I have found in practice that, in the use 70 teristics in the general purposes for which of the two binding materials having the it is employed. character above set forth, in the relative pro- My composition consists primarily of the portions governed by the type of filling mafollowing ingredients: a fibrous filling material employed and the intended uses of the terial, a soluble liquid binding fluid, and a ompleted Pr in h new p o 111- 7 5 solid binding material. position constituting my invention, the de- The type of fibrous filling material em sirable properties which are latent in each ployed may be varied according to the inof these respective binding materials are detended uses to which the finished product is veloped in the final product, and at the same to be applied, while the two binding eletime there is eliminated or diminished the 80 ments are constant as regards the types of undesirable properties which would result materials employed but vary as to their relafrom the use of one of said binding matetive proportions, such variation in the relarials alone. For instance, in producing a tive proportions of the two binding elements fireproof composition material to be used as being governed by the type of the fibrous a substitute for wood, the desirable proper- 85 filling material employed and the intended ties include strength, resilience, facility in uses of the finished product. working with wood-working tools, and re- Any suitable fibrous filling material may sistance to fire or hea These properties are be employed. For instance, where fire-reobtained in the composition mainly through sisting properties of high degree are desirthe use of the soluble silicate binding ele- 90 able, the preferred fibrous filling material is ment. Other requisite properties, which the asbestos fiber and where fire-resisting propuse of a soluble silicate as a binder does not ertles oi a lower degree are desired, or it is produce, are resistance to the action of water desired to produce a finished product which and frost (especially where the finished is of lighter weight and less expensive and product is to be used in building construc- 95 i more easily worked under the ordinary contion in exteriorly exposed positions, such as ditions of carpentry, a fibrm gaggtahlejllits use for shingles or outside trim), and the ing material, such as sawdust may be emadaptability to take the regular paints as ployed. used in building operations without the 'l:he t wo binding elements, which are conpaint becoming discolored or otherwise de- 1 0 stant as regards the types of materials emteriorated. The employment of the other ployed, preferably consist of a sgluble silgbinding element, a cement having a substancate. as the soluble liquid binding u1 an tial proportion of calcium oxid, which is as e solid binding material, a substance iii used in my composition in association with which calcium oxid occurs as the mainconthe solublelisilicate, obtains these lattenrequi- 105 stituent 1n such proportion that the binding site-propetties in the completed product, and

material of which the calcium oxid is a part at the same time has important and advanis adapted to harden as a whole when tageous effects in the processes employed in brought into association with the mass of the manufacture of the composition product. the composition under proper conditions If the cement binding element were alone 110 with water. employed, the properties obtained in the re- The soluble silicate binding material sulting composition would be unsatisfactory,

in that the composition would lack resilience, offer too great resistance to wood-working tools, and be relatively low in fire-resistance. Thus, in the employment of the two binding elements having the properties as above set forth, in my composition, the disadvantages incident to the use of either of the binding materials alone are obviated, and at the same time important advantages are secured.

In connection with the above explanation of the advantages obtained by the use of the two binding materials having the character set forth, in my composition, it will be observed that the successful use of the cement as a sole binding element, with such fibrous materials as asbes or sawdust, would be impossible unless the cement were used in a very large or excess proportion with relation to the fibrous fillingmaterial, which conditions arise'from the fact that there is only an imperfect bond between cement and asbestos and practically no bond between cement and such vegetable fibrous materials as sawdust. If, therefore, the very large or excess proportion of the cement, which would be essential under the conditions just noted, were employed, the resultant composition product would essentially have the properties of hardened or set hydraulic cement and be of a stone-like nature, which would not be adapted for the uses for which the product constituted by my composition is designed to serve and be adapted. Also, the use of the soluble silicate alone, as a binding material, would be ineffective, for the reason that the completed composition product would then be deficient in resistance to the action of water and frost and would deleteriously affect ordinary paint applied to its surface. The manufacture of the composition product, under conditions involving the use of the soluble silicate as a sole binding material, would also be attended with difficulties, all of which disadvantageous conditions and circumstances are obviated by the addition of the cement ingredient, as a binding element in conjunction with the soluble silicate binding fluid, within the range of the relative proportions which are preferably as hereinafter set forth.

In further explanation of "the advantages resulting from the employment of the two binding materials of the character herein set forth, it may be stated, with reference to the employment of a soluble silicate as a sole binding material for the filling material, that when the filling material is mixed with a soluble silicate, such as silicate of soda, and exposed to the air at ordinary temperatures, evaporation of the water in the composition mass wherein the silicate is dissolved commences and the solidification of the surface of the composition product results. This surface solidification retards the evaporation of the water in the body mass of the composition, and the desired complete solidification of the body mass of the complete product, when the latter is of an appreciable or average thickness for the purpose for which these types of fireproof composition products are designed to be used (as, for instance, inch), would result under exposure to the atmosphere only after a long period. Furthermore, the silicate will then have lost only a certain proportion of the water in which it was di solved, and upon submersion in or subjection to the action of water the silicate will re-dissolve, and its efficiency as a binding agent will be thus reduced or destroyed.

In previous compositions of the character to which my present invention relates, the disadvantages or difficulty just stated is partially overcome by subjecting the body mass of the composition product to a high degree of artificial heat, to evaporate or drive off the moisture, but the formation as above noted of a substantially solid surface'shcll around the internal body mass of the composition resists the elimination of the moisture or water by this means, and the steam which is generated in the mass exerts a pressure which causes the solidified surfaces of the composition product to be fractured or deteriorated. For the reason just stated, it has been found necessary, in the manufacture of composition productsof the class noted, to subject the body mass of the composition to the action of heat in a confined space and under pressure (as, for instance, between heated former plates in a press), and to at the same time provide for the passage of the moisture and generated steam from the body mass, conditions of which character are set forth in the prior Letters Patent issued to James A. WVheeler, reissue No. 13,446, dated July 16, 1912, and No. 1,048,616, dated December 31, 1912, to which reference may be had for a more complete understanding of the conditions which are overcome by the composition of my present invention in which the two binding materials, to wit: a soluble silicate as-a fluid binder and a cement having a substantial proportion of calcium oxid as a solid binder, are employed.

I will now proceed to describe in further detail the ingredients or elements of my composition and the preferred range of the proportions thereof, and the manner of mixing or associating the same and producing the complete composition product. To the fibrous filling material (which may be asbestos fiber, sawdust, or other suitable fibrous material or combination thereof) is first added a relatively large proportion by weight of the binding material consisting of the two elements, to wit: a soluble silicate (which may be a solution of sodium silicate 106. COMPOSITIONS,

COATING R PLASTIC.

or potassium silicate) and a cement having a substantial proportion of calcium oxid (which may be Portland cement, slag cement, natural cement, or other suitable hydraulic cement), the soluble silicate binding fluid and the cement solid binder being first thoroughly intermixed or mingled, by agitation or in any suitable manner, to produce the composite binding material. The filler and composite binder elements are thoroughly intermixed or. mingled, by agitation or in any other suitable manner, in combination with a suitable amount of water in which the soluble silicate is dissolved, to produce a homogeneous plastic mass of the desired consistency. The plastic body mass of the composition is then subjected at ordinary temperatures to the action of pressure to mold the mass into the desired form according to the specific use for which the completed product is intended, and to compress the mass to the desired degree of density and accelerate and assist the setting of the cement binding element. The pressure is applied for a comparatively short period, and is varied in intensity according to the degree of density desired in the completed composition product. The composition body mass is then removed from the pressure and molding action above set forth and is placed under subjection for a suitable period to ordinary temperatures, or to a somewhat higher temperature up to approximately 100 F. if preferred, during which period the hardening of the cement binding element to the point known as the final set is permitted. The composition body mass may then, if desired, under conditions of uses for which the product is intended, be subjected to gradually rising temperatures, to eliminate more rapidly the desired amount of moisture from the soluble silicate and to accelerate the development of the set strength in the cement binding element.

As soon as the ingredients of my composition are intermixed and mingled in relative association in a plastic mass, the action which insures the advantages resulting from the new composition as herein described becomes operative. The soluble silicate bonds with the fibrous filler, and the cement element bonds with the soluble silicate. The affinity of the cement binding element for water results in the absorption of a large amount of water which becomes part of the cement during the process of setting, and immediately when the water in which the soluble silicate is dissolved comes in contact with the cement hydrolysis commences, the cement taking water from'the silicate. The subjection of the plastic body mass of the composition to pressure results in bringing all the particles of the filler and binding elements into closer association and aids the crystallization of the cement binding element. hen the composition body mass is withdrawn from the pressure action and is retained at ordinary temperatures and under exposure to the air, the silicate immediately commences solidification at the surface of the body mass, and the internal mass of the latter is in a manner sealed or protected from the action of the air, which results in the conservation of the moisture in the internal mass which is required for absorption by the cement element. The setting of the cement under the most effective conditions is thus insured, and the action of the cement in taking water from the sili cate solution results in developing the strength and resistance of the silicate binding element. Furthermore, under the subjection of the composition body mass to pressure, and the presence of the free alkali which exists in a small percentage in the silicate binding element, the cement sets more rapidly than it would if mixed with water alone, and therefore at this stage of the mixing of the composition body mass and the subjection of the same to pressure there is produced in a comparatively short time a composition product of effective physical strength. After the cement binding element has taken its so-called final set, the subsequent subjection of the composition body mass to higher temperatures results in the heating of the cement in the presence of moisture, which accelerates its hardening and development of strength, and under this heating of the composition mass for a comparatively short period the strength of the cement binding element, which is present in association with the soluble silicate binding element, is increased to a degree which would not be obtained in a very much greater period of time if the composition body mass were merely retained under subjection to ordinary temperatures. Also, under the subjection of the composition body mass to the action of heat as above described, the water or mois ture is driven oil from the silicate solution and the latter becomes a practically insoluble mass, while the steam or moisture which is thus set free is confined by the solidified condition of the surfaces of the composition body mass, as above referred to, and is ab sorbed by the cement binding element in its hardening process. Hence. the composition body mass is dried and hardened throughout in a thorough, efficient, and efi'ec'tive manner under rapid and simple conditions.

I have further found, in practice, that when my new composition body mass has been heated until the presence of moisture or Water in the internal mass has been practically eliminated, the silicate binding ele ment becomes strong and practically in soluble in water, but that there remains in the silicate binder a small amount of free mains constant in its proportion to the hindspectively set forth theapproximate minimum and maximum range of the proportions of the two binding elements with relation to the fibrous filling material under the various conditions which generally arise in securing the properties demanded in the completed product according to the conditions of specific use for which it is intended. In these examples, the proportions are given by weight, and the proportion of the fibrous filling material remains constant in relation to the variable relative proportions of the two combined binding elements.

The approximate example of the composition in which is employed the minimum of the range of the proportions of the calcium alkali which is soluble in water and which in the presence of any moisture remaining in the body mass appears on the surface of the product and would exert a deleterious efi'ect on any oil paint applied thereto. However, counter to this action of the silicate binder, the cement binding element attains ultimately a higher degree of strength if it has aged in the presence of moisture or in water. These counteractions are made available and direct advantages are secured, in my new composition, by the employment in association of both the silicate binding element and the cement binding element, in lieu of the employment of either of such binding elements alone, for, after the composition body mass has been formed under the conditions hereinabove described, the submerging of the composition product in water for a suitably extended period will of the proportions of the soluble silicate element is as follows:

Fibrous filler 30% result 1n an action in w h1ch the ob ection- Cement binder, of a yp containing able free alkali remaining 1n the silicate 60% y Weight of calcium oxid bmder 1s dissolved from the mass and at the Soluble silicate binder same time the value of the cement element as a binder is enhanced.

In the relative proportions employed, it will be understood that with any specific type of the fibrous filling material there will be one best ratio of the cement binding ele- The approximate example of the compositiion in which is employed the maximum of the range of the proportions of the calcium oxid element and the minimum of the range of the proportions of the soluble silicate element is as follows:

ment and the soluble silicate binding element to attain the highest physical strength in the completed product. But other prop- 53 2 2 33;;"a 'gig fig'ggfiagg 30% erties 1n the completed product, under the 60% by weigilt of calcium oxid 40% varlous conditions of use for whlch 1t 1s Soluble Silicate binder 30% designed, may be -more important than physical strength, for instance, in certain product resilience and workableness with wood-working tools, and in other certain product the reverse conditions of rigidity and hardness, and it will therefore be understood that a variation in the ratio of the binding elements to the fibrous filling material will be employed according to the particular conditions of use for which the completed composition product is employed. This variation in proportions is in the proportions of the two respective binding elements with relation to each other and to the fibrous filling material, while the latter re- It will therefore be understood that the relative proportions in my new composition may be varied according to the specific purposes for which the completed product is to be used, and that such variation is within the scope of my invention and improvements.

Having thus described my invention, I claim and desire to secure by Letters Patent:

1. A composition for use as a substitute for wood in building construction, consisting of a fibrous filler mixed with a composite binder the mass of which is in relatively larger proportion by weight than the filler and is constituted by both a soluble silicate binding element and a cement binding element.

2. A composition for use as a substitute for wood in building construction, formed by mixing a fibrous filler with a mass of a composite binding element consistin of a mixture of a soluble liquid silicate binding ingredient and a solid cement binding in-.

edient.

3. A composition for use in building construction, consisting of a fibrous filler mixed with a composite binder the mass of which is constituted by a soluble silicate bindi e ment dissolved in water and a solid cement binding element, the relative proportions of ing mass; Thus, if in thecompleted product the dominant properties desired are resilience, maximum fire-resistance, and facility in working with edged tools, then the cement binding element is suppressed in relation to the soluble silicate, but if greater hardness and rigidity is desired in the completed product the proportion of the cement bindelement is increased and that of the so .uble silicate decreased.

The preferred variable proportions are regulated by the character of the cement binding element in its content percentage of calcium oxid, and in illustration I have herein given two examples in which are reoxid element and the maximum of the range 106. comPos mows,

comma 0R PLASTIC.

the elements of said composite binder being such that the water in which the silicate is dissolved equals the amount required by the cement to set and harden it.

4. The method of producing a composition for use as a substitute for wood in building construction, which consists in making a composite binding mass by mixing a soluble silicate binding element with a cement binding element, and then mixing said composite binding mass with a fibrous filler.

5. The method of producing a composition for use as a substitute for wood in building construction, which consists in 15 making a composite binding mass by mixing a soluble silicate binding element with a cement binding element, and then mixing said composite binding mass with a fibrous filler in relative proportions by weight in which the proportion of said composite silicute and cement binder is in excess of the proportion of the filler.

In testimony whereof I have signed my name in the presence of the subscribing witnesses.

WILLIAM H. WHEELER.

Witnesses:

IRWIN WHEELER, MAX E. SANDERS.

copies of this patent may he obtained to: five cents each, by addressing the "Commissioner of Patents, Washington, D. 0. 

